Functionally substituted terpolymers and tetrapolymers of &#39; -olefins and process for manufacturing functional substituted copolymers

ABSTRACT

Addition terpolymers of ethylene with an Alpha -olefin and an unsaturated, functionally substituted monomer. Addition tetrapolymers of ethylene with an Alpha -olefin having 3-18 carbon atoms, a nonconjugated diene having only one polymerizable double bond, and an unsaturated, functionally substituted monomer. A process for preparing copolymers of ethylene with an unsaturated functionally substituted monomer, and optionally also with at least one of the following: an Alpha -olefin having 3-18 carbon atoms and a nonconjugated diene having only one polymerizable double bond; wherein the monomers are contacted in the presence of a vanadium compound soluble in hydrocarbons and chlorinated hydrocarbons, in which vanadium is in the oxidation state of at least +3, an organoaluminum compound, and an organic compound having at least one carbon atom substituted by three halogen atoms which can be chlorine or bromine.

United States Patent Collette et al.

FUNCTIONALLY SUBSTITUTED TERPOLYMERS AND TETRAPOLYMERS OF a-OLEFINS AND PROCESS FOR MANUFACTURING FUNCTIONAL SUBSTITUTED COPOLYMERS Inventors: John Wilfred Collette; Rolland Shih-Yuan R0; Fred Max Sonnenberg, all of Wilmington, Del.

Assignee: E. I. Du Pont de Nemours and Company, Wilmington, Del.

Filed: Sept. 27, 1974 Appl. No.: 509,896

Related U.S. Application Data Continuation of Ser. No. 355,011, April 27, 1973, abandoned, which is a division of Ser. No. 829,758, June 2, 1969, abandoned.

U.S. Cl 260/8038; 260/47 UA; 260/63 R; 260/63 BB; 260/793 MU; 260/8073;

Int. Cl. C08f 15/40 Field of Search 260/8078 References Cited UNITED STATES PATENTS 12/1969 Mortimer 260/8073 3,492,277 1/1970 Clark 260/88.1 3,551,524 12/1970 Stein 260/880 3,687,909 8/1972 Vaughn 260/8078 3,723,399 3/1973 Arniard et al...... 260/8073 3,796,687 3/1974 Collette et al. 260/47 UA Primary Examiner-Lester L. Lee

[ 5 7 1 ABSTRACT Addition terpolymers of ethylene with an a-olef'm and an unsaturated, functionally substituted monomer. Addition tetrapolymers of ethylene with an a-olefin having 3-18 carbon atoms, a nonconjugated diene having only one polymerizable double bond, and an unsaturated, functionally substituted monomer. A process for preparing copolymers of ethylene with an unsaturated functionally substituted monomer, and optionally also with at least one of the following: an a-olefin having 3-18 carbon atoms and a nonconjugated diene having only one polymerizable double bond; wherein the monomers are contacted in the presence of a vanadium compound soluble in hydrocarbons and chlorinated hydrocarbons, in which vanadium is in the oxidation state of at least +3, an organoaluminum compound, and an organic compound having at least one carbon atom substituted by three halogen atoms which can be chlorine or bromine.

2 Claims, No Drawings FUNCTIONALLY SUBSTITUTED TERPOLYMERS AND TETRAPOLYMERS OF a-OLEFINS AND PROCESS FOR MANUFACTURING FUNCTIONAL SUBSTITUTED COPOLYMERS This is a continuation, of application Ser. No. 355,011, filed Apr. 27, 1973, and now abandoned, which in turn is a divisional of application Scr. No. 829,758, filed June 2, 1969 and now abandoned.

BACKGROUND OF THE INVENTION This invention relates to a new copolymerization process and to new terpolymers and tetrapolymers having functional groups which can be obtained thereby.

It is well known to copolymerize certain olefinic and vinyl monomers in the presence of ree-radical generating initiators. Some olefinic monomers, such as propylene, isobutylene, and butene either cannot be polymerized at all in the presence of free-radical initiators or can be polymerized only to low molecular weight polymers. Polymerization of diolefins or divinyl compounds by a free radical process leads to highly crosslinked polymers which are of limited practical value.

Coordination catalysts, which allow a much better control of the polymerization process, often are not suitable for use with monomers having functional groups containing elements other than carbon and hydrogen. Usually, coordination catalysts tend to complex with polar functional groups and such complexed catalysts either become completely deactivated or decay at a fast rate.

Copolymers of olefinic monomers with several monomers containing functional groups have been reported. Terpolymers of ethylene with propylene and certain unsaturated acid amides, nitriles, anhydrides, and esters have also recently been described in U.S. Pat. No. 3,278,495. However, neither terpolymers of ethylene and a-olefins with monomers containing other functional groups nor tetrapolymers of ethylene with a-olefins, dienes and functional monomers are known.

SUMMARY OF THE INVENTION Accordingly, it has now been discovered that novel elastomerie ethylene random terpolymers with oz-olefins having 3-18 carbon atoms and unsaturated functional monomers and of tetrapolymers with nonconjugated dienes having only one polymerizable double bond can be readily made using a coordination catalyst based on a vanadium compound, in which the vanadium is in the oxidation state of +3 or higher. Random distribution of the monomer units in a terpolymer or tetrapolymer molecule is often useful for good elastic properties of the material. An aluminum aryl or alkyl or an arylor alkylaluminum chloride or bromide also is present. When the functional groups of the monomer contain either oxygen or nitrogen, the molar concen tration of the organoaluminum compound is at least equal to that of the functional monomer. Reduced vanadium is regenerated by an oxidizing agent which is preferably an organic compound having at least one carbon atom substituted by three halogen atoms selected from chlorine and bromine. The copolymerization is run in solution in an organic solvent.

The following monomers having functional groups can be copolymcrized with ethylene and optionally also with an a-olefin. a nonconjugated diene. or both, by the process of the present invention:

1. Compounds of the formula I where X can be one of the following groups: OR, 2.

ll O-CCF;|.

-F, Br, or Cl and R can be alkyl, aryl, or cycloalkyl containing 1-18 carbon atoms, or hydrogen;

2. Compounds of formula II where Y can be one of the following groups:

(III) SO Cl, where R can be alkyl, aryl or cycloalkyl, containing [-18 carbon atoms, or hydrogen; R can be either R or OR.

3. Compounds of the formula [I] r -nrz.

where Z can be either X [as defined in 1) above] or Y [as defined in (2) above]; and

4. Compounds of the formula [V n 0-21) Ill -Continued where R, R,, m and n have the same meaning as in formulas l-IV, above; these functional monomers all are derived from, and are special cases of, the broader classes of monomers represented by formulas l-lll.

DETAILED DESCRIPTION OF THE INVENTION Copolymerization of ethylene with a functionally substituted monomer optionally also with an a-olefin, a nonconjugated diene, or both can be run either batchwise or continuously, at either atmospheric or superatmospheric pressure. A solvent usually is employed. although it is not absolutely necessary. Good solvents are aliphatic hydrocarbons such as pentane, hexane, heptane, octane, and isooctanes', cycloaliphatic hydrocarbons, such as cyclopentane, cyclohexane, cycloheptane, and cyclooctane; and halogenated aliphatic hydrocarbons, for example, perchloroethylene, carbon tetrachloride, methylene chloride, and chloroform.

The reaction catalyst is composed of the following constituents:

a. A vanadium compound in which vanadium is in an oxidation state of +3 or higher; for example, VCl vOCl vanadium tris-(acetylacetonate); vanadium halide complexes with ethers, amines, or phosphines (for example complexes of VCL, with dioxane, pyridine or triphenylphosphine and esters and haloestcrs of vanadic acids (such as diethoxyvanadium dichloride, triethyl vanadate, or dicthoxyvanadium oxychloride). The vanadium compound should be soluble in hydrocarbons and chlorinated hydrocarbons.

b. An organoaluminum compound of the structure (R ),,Al, (R );,A1 L;,, (R AIL, or (R )AlL where R.

is any] or a C C alkyl, such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, or hexyl; and L is chlorine or bromine.

Representative organoaluminum compounds include: triisobutylaluminum, diisobutylaluminum monochloride, triethylaluminum, diethylaluminum chloride, ethylaluminum sesquichloride, diethylaluminum bromide, ethylaluminum dichloride, propylaluminum dibromide, and triphenylaluminum.

c. A halogenated compound of the general formula DCL where L has the same meaning as above, while D can be hydrogen, chlorine, bromine, alkyl, aryl, haloalkyl, haloaryl, carboxyl, alkoxycarbonyl, aryloxycarbonyl, alkylcarbonyl, arylcarbonyl, alkoxy, aryloxy, haloalkoxycarbonyl, haloaryloxycarbonyl, haloalkylcarbonyl, haloarylcarbonyl, haloalkoxy, haloaryloxy, or the group where A, A and A each can independently be a halo gen, alkyl, haloalkyl, aryl, haloaryl; and A also can be hydrogen.

Representative halogenated compounds are, for example, chloroform, bromoform, carbon tetrachloride, a,a,a-trichlorotoluene, a,a,a-tribromotoluene, trichloroacetic acid, tribromoacetic acid, perchloropropylene, hexachloroacetone, ethyl trichloroacetate and ethyl tribromoacetate.

Normally, at least 2 moles of organoaluminum com pound are present for each mole of vanadium compound. However, the preferred ratio is about 10:! or more. Organoaluminum compounds required in this process are decomposed in the presence of monomers having active hydrogen atoms, such as carboxylic acids or alcohols, Furthermore, they are complexed and deactivated by oxygenand nitrogen-containing polar groups. It is, therefore, advantageous to have in the mixture a sufficient amount of the organoaluminum compound to at least compensate for its decomposition or deactivation. An excess of the organoaluminum compound is not harmful, and molar ratios of aluminum to vanadium compounds as high as 200:1 or more can be present in the catalyst.

The halogenated compound DCL acts as a catalyst reactivator and it can be present in a large excess, for instance, in an amount of 10 moles per mole of vanadium compound. However, the amount of the reactivator should be kept within the range of about 0.0l-l mole per mole of the organoaluminum compound present in solution. Below the lower limit the reactivation of the vanadium catalyst is not quite efficient, while above the upper limit there is a risk that polymerization may proceed by an undesirable ionic mechanism. The vanadium compound is present in catalytic amounts only, for example, 0.000050.005 mole per mole of total unsaturated monomers.

The practical concentration ranges of the essential compounds in the present copolymerization process are tabulated below:

TABLE I Concentration Compound moles/l. Remarks Vanadium catalyst 0.0000l0.00l Functional monomer 0.000l-4Ll Organoaluminum 0.00l-(Ll must he at least compound equal to the concentration of oxygcnand nitrogen-containing groups Catalyst reactivator 0.000(ll-(Ll must he at least equal to vanadium catalyst concentration Polymerization is run in the absence of moisture in an inert atmosphere, for example in dry nitrogen, and at a temperature of to 125C. The preferred temperature range is 0-65C. Below 0C. it is both inconvenient and expensive to remove heat evolved during the polymerization. Above about 65C. the molecular weight of the copolymer product can fall below a desirable value. It is usually convenient to carry out the copolymerization at atmospheric pressure, but reasons of economy of time or equipment may sometimes favor closed system polymerizations at autogenous pressures or higher. It is usually possible, for example. to increase the monomer concentration in solution in a closed systern, and a smaller reactor, therefore, can be used than at atmospheric pressure. When polymerization is run in a closed system, pressures up to about 10,000 psig. can be used, but it is not practical to exceed a pressure of about 5,000 psig,

Although the process of the present invention is susceptible to changes and variations without departing from the spirit of the inventive concept, a typical batchwise atmospheric pressure copolymerization involves the following steps: ethylene, and optionally a comonomer a-olefin, are dissolved in an appropriate solvent such as perchloroethylene, and an alkylaluminum compound is added. This is followed by addition of an unsaturated functional monomer, optionally a diene, then a catalyst reactivator and finally, a vanadium compound. The solution is stirred for about 30 minutes, while ethylene and any gaseous monomers are continuously swept through it. The polymerization is stopped by destroying the catalyst system, for example by adding an alcohol. The reaction time in some cases may be as short as 1 minute, while in other cases a period of 2 hours or more may be required to obtain satisfactory yields of the copolymer.

The process of the present invention can also be operated in a continuous manner. It often is desirable in such a case to increase the reaction pressure in order to reduce the residence time. The reactor effluent is continuously removed.

The product copolymer can be isolated by several known techniques, but it is preferred to precipitate it with a non-solvent such as methanol and to wash it. The functional groups ofa crude copolymer often retain residual aluminum compounds, and, since a copolymer containing residual aluminum is unsuitable for most applications. removal of any aluminum compounds pres ent is advisable. Where a copolymer is precipitated from solution with an alcohol, it usually is sufficiently free from aluminum, but when the copolymer contains carbowlic groups. it may be necessary to remove the last traces of aluminum compounds, for example by a treatment with trifluoroacetic acid. When other isolation methods are used, for example evaporation or phase decantation, it is practical to remove residual aluminum compounds by washing the copolymer solution with a large excess of a dilute acid, such as sulfuric, hydrochloric, or acetic acid and to remove the acid by washing with water.

Alpha-olefins which can be used as comonomers in the process of the present invention can be either straight-chain or branched. Representative a-olefins include propylene, butene, pentene, hexene, heptene, decenc and octadecene. Propylene is the preferred a-olefin. Nonconjugated dienes which have only one polymerizable double bond can be present in addition to a-olefin comonomers. These include 1,4-hexadienc, 5-methylene-2-norbornene, 5-( Z-butenyl )-2- norbornene, dicyclopentadiene, 5-ethylidene-2- norbornene, ll-ethyl-l,ll-tridecadicne, and l,5- heptadiene.

The unsaturated functional comonomers can have active hydrogen atoms. provided at least a stoichiometric amount of aluminum alkyl or alkylaluminum halide also is present to prevent catalyst deactivation. Generally, the farther is the functional group removed from the double bond, the easier and more complete is the copolymerization of the functional comonomer. Typical compounds of the group defined by Formula I include 4-pentene-l-ol, S-hexene-l-ol, IO-undecene-lol, 4-pentenyl methyl ether, S-hexenyl methyl ether, 5-hcxenyl dicthylamine, o-heptenyl methylethylamine, 4-pentenyl trifluoroacetatc, 6-heptenyl trifluoroacetate, 4-pentenyl methyl ketone, S-hexenyl methyl kctone, 6-heptenyl vinyl ketone, IO-undecenyl chloride, o-heptenyl chloride and 4-pentenyl acetate. When the unsaturated functional monomer is a member of the group defined by formula II, it can be, for example, one of the following compounds: acrylic acid, methacrylic acid, vinylacetic acid, lO-undecenoic acid, allylacetic acid, methyl acrylate, ethyl acrylate propyl acrylate, methyl methacrylate, ethyl methacrylate, butyl l0- undecenatc, ethyl vinylacetate, propyl vinylacetate, methyl allylacetate, butyl allylacetate, N,N- dirnethylacrylamide, acrylamide, N,N-diethyl vinylacetamide, acrylonitrile, methacrylonitrile, 2- allylphenol, 2-methoxy-4-allylphenol, allylsulfonyl chloride and S-norbornene-Z-sulfonyl chloride. The unsaturated functional monomer can also be a 2- norbornene derivative, as shown in Formula Ill. It thus can be, for example, 2-norbornene-5-acetic acid, 2-norbornene-5-propionamide, 2-norbornene-5- methanol, 2-norbornene-5-ethyl methyl ketone, Z-norbornene-5-acetonitrile, or ethyl 2-norbornene- S-acetate. Monomers having structures represented by formula IV include, for example, 8-phenoxy-l,6- octadiene; 9-( 2'-hydroxy )phenoxyl ,o-octadiene; 8- (4'-chloro )phenoxyl ,o-octadiene; 8-( 4'-methyl phenoxy-lboctadiene; and 8-(4-methoxy)phenoxy- 1,6-octadiene. All these compounds are known in the art.

Although the proportions of comonomers can be varied, it is preferred to maintain the amount of a-olefin (when present) at such a level that it will constitute 5-75 weight percent of the product copolymer. preferably about 2060 weight percent. Functional unsaturated monomer is prcsent in such an amount that it will constitute 0.1l() mole percent of the product. When a nonconjugated diene is used in addition to ethylene and optionally a-olefin, it generally is employed at a level which will give 0.1- mole percent diene component in the final copolymer. The amount of ethylene can be varied within rather broad limits, so long as the above proportions are maintained.

The novel copolymers of the present invention have desirable physical and chemical properties which make them useful for a number of applications. Thus, for example, the solubility and dispersibility of an olefinic polymer are modified by the presence of functional groups. A copolymer having functional groups is more compatible with polar solvents than a hydrocarbon polymer. Carboxyl groups impart good abrasion resistance, allow formation of stable latices. and improve adhesion. Hydroxyl groups provide active sites which allow crosslinking and/or chain extension, for instance with polyisocyanates. Other functional groups, such as amino groups, improve dyeability of a copolymer. These new terpolymers and tetrapolymers are very useful in adhesives, especially when a nonpolar material must be bonded to a polar substrate (e.g., when bonding elastomer stocks to tire cords).

This invention will be better understood if reference is made to the following examples of some specific embodiments thereof, where all parts, proportions and percentages are by weight, unless otherwise indicated.

EXAMPLES General Copolymerization Procedure for ethylene/propylene/functional monomer terpolymers Batch polymerizations are carried out at atmospheric pressure in an oven-dried 3-necked IOOO-ml. flask equipped with a serum cap, a stirrer and a thermometer. The flask is swept with nitrogen and filled to the 500 ml. mark with perchloroethylene at about 15C. Ethylene and propylene are first swept through the solvent for 10 minutes at the rate of l l./minute and 2 L/minute, respectively.

In a typical experiment, while ethylene and propylene are continuously introduced at the above rates, 5 ml. ofa 4M solution of diethylaluminum chloride (0.02 mole) in perchloroethylene is added through the serum cap, followed. in turn, by a solution of 0.01 mole of unsaturated functional monomer in ml. of perchloroethylene and 1 ml. of a 1.0M solution of hexachloropropylene (0.001 mole) in perchloroethylene. The temperature is adjusted to C. and 1 ml. of a 0.1M solution of VCl in perchloroethylene (0.00l mole) is added.

The temperature is maintained at 2030C., cooling the flask in an ice bath, as necessary. After 30 minutes, from addition of VCl polymerization is terminated by the addition of 3 ml. of isopropyl alcohol.

Workup involves removing a l0O-ml. sample and adding it dropwise to 500 ml. of methanol in a blender to precipitate the polymer; the liquid is subsequently decanted. Another 500 ml. of methanol is used to wash the polymer. The isolated polymer is dried at C. for at least 3 hours in a vacuum oven.

When the copolymer contains carboxylic groups, the copolymer solution can be treated with trifluoroacetic acid (TFAA) to remove last traces of the catalyst. The solution (250 ml.) is mixed with 30 ml. of TFAA and allowed to stand overnight. The solid catalyst residues are filtered; and the filtrate is treated with 10 ml. of TFAA and filtered immediately. The filtrate is concentrated in a rotary vacuum evaporator and the solution washed three times with ml. of water. The organic layer is further concentrated to about 100 ml. and added dropwise to 500 ml. of vigorously stirred acetone. The precipitated polymer is decanted and dried in a vacuum oven for at least 3 hours at 90C.

The results of experiments l-lO run both with and without hexachloropropylene (HCP) (as catalyst reactivator) are presented below in Table II.

TABLE Il Yield of copolymer from norhornene Control experiments. outside the scope of this invention. "In this experiment, 0.02 mole of ethylaluminum dichloride is used.

General Copolymerization Procedure for ethylene/propylene/ 1 ,4-hexadiene/functional tetrapolymers The procedure described above for the preparation of terpolymers is used with slight modifications. Ethylene and propylene are introduced into perchloroethylene at 5C. at the rate of 1.5 l./min. The amount of diethylaluminum chloride is increased to 25 ml. (0.l0 mole) and the amount of functional monomer to 0.05 mole. 1,4-Hexadiene, 12 ml. (0.10 mole) is added through the septum. The amount of 0. l M VCL, is 3 ml. (0.0003 mole), and 3 ml. of 1.0M (0.003 mole) hexachloropropylene is added at -5C. The tetrapolymer is recovered by precipitation with 2 liters of methanol and washed with 2 liters of methanol. The copolymer is vacuum oven-dried overnight at 60C. The results are presented in Table III.

TABLE lll ii lncorpuration h Copolymcr Wt of FA. yield. monomer in lnsaturation Nu. Functional Monomer grams Copolymer mules kg ll ('H. .=('H(( 'H. .I UH 40.1 1.1 0.119

(H. .CH='(H. l .5 l 5 (1.6)

strong hand evident in IR spectrum "U15 mole lirdi 'lh flillulllillunl chloride used Adhesion testing of Functional Tetrapolymers Hard Kaolin Clay in accordance with ASTM Method D-4l2-66.

The results are presented in Table IV. below:

TABLE 1V Unsutu- Wt. Z of lnh.

ration. propylene Visc.. T Ex. molcs/ in tctruat No. Functional Monomer kg. polymer 30C) psi.

l6 4-Vinylpyridine 0.75 25.3 (1.98 5 l0 l8 Z-Hydroxymcthyl- 0.17 33.0 1.45 2H) S-norhnrnenc Con- None (1.40 42.4 7 17 Si) trul" As :1 solution ul'tLl g. of tetrapolymer in lilll ml. lIfpLIUh|0l'Ul-"h)i0llc "teti'an'mly niur mutli: h a continuous process "'a prior art tcrpulynlcr liming (.33 mole/kg. unsulurntiun. and containing the folloiaing monomer unit composition: ethylene. 52.]; propylene. 44.0. IA-hcxudicne. 3.). ll is made in perchlomcthylenc in the pre ence ul n coordination catalyst formed by prcmixing tliisnhulylaluminuni chloride uml \'O('I The Mooney \iscusit) (ML-lH/IZIK.) is about 4ll.

Suprex" Clay. (J. M. Huber Corp., New York) is an air-floated hard kaolin type characterized by the following equivalent analysis: 44-46 percent silica, 37.5-39.5 percent alumina. [5-2 percent iron oxide, and 1-2 percent titanium dioxide by weight, the ignition loss being 13.9-l 4.2 percent by weight. This analysis does not mean that the clay necessarily contains silica or alumina. The moisture content (maximum) is 1 Q percent by weight. The pH (in water) is about 4.5-5.5.

This clay has a specific gravity of 2.60, a 325-mesh screen residue of 0.17 percent by weight, and the following particle size distribution (by weight):

10 pi, 0.1%; 5-l0 11., 2.8%; 4-5 p, 3-4 p., 2.3%; 2-3 41., 3.4%; 1-2 p, 9.0%; 0.5-1 p, 10.0%; O-O.5 1.4., 6l.9%.

Adhesion of ethylene/propylene] 1 ,4-hexadiene/functional monomer tetrapolymers towards Suprex Clay is determined in the following manner:

The tetrapolymer grams) and Suprex Clay (24 grams) are compounded on a rubber mill. The compounded polymer is loaded cold into a l X 5 inch slab mold and heated at lOOC. for 3 minutes. The specimen is allowed to cool, unloaded, and the tensile strength at break T is determined at 25C. on an Instron machine These results show that even the unvulcanized tetrapolymers give tough and strong clay-filled compositions. Tension at break is indicative both of adhesion of the tetrapolymer to the clay and of internal cohesion of the tetrapolymer itself. Comparison with a control terpolymer not containing functional groups shows the low T value obtained for such a terpolymer.

We claim:

1. An elastomeric addition copolymer consisting essentially of l ethylene, (2) propylene. and (3) an unsaturated functional monomer of the formula wherein Z is 0 ll C-OH and n is 0-20.

2. An addition copolymer of claim 1 wherein the unsaturated functional monomer is 5-norbornene-2- acetic acid. 

1. AN ELESTOMERIC ADDITION COPOLYMER CONSISTING ESSENTIALLY OF (1) ETHYLENE, (2) PROPYLENE, AND (3) AN UNSATURATED FUNCTIONAL MONOMER OF THE FORMULA
 2. An addition copolymer of claim 1 wherein the unsaturated functional monomer is 5-norbornene-2-acetic acid. 